Ford 2007 Low Cab Forward Owner's manual

Introduction 4

Vehicle Inspection Guide 11

Instrument Cluster 18

Warning lights and chimes 18

Gauges 23

Entertainment Systems 26

AM/FM stereo 26

AM/FM stereo cassette 28

AM/FM stereo with CD 31

Climate Controls 36

Heater only 36

Manual heating and air conditioning 37

Lights 40

Headlamps 40

Turn signal control 45

Bulb replacement 45

Driver Controls 51

Windshield wiper/washer control 51

Steering wheel adjustment 51

Power windows 51

Mirrors 53

Speed control 53

Locks and Security 57

Keys 57

Locks 57

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Seating and Safety Restraints 61

Seating 61

Safety restraints 62

Child restraints 67

Driving 73

Starting 73

Brakes 76

Transmission operation 80

Vehicle loading 86

Trailer towing 89

Roadside Emergencies 93

Getting roadside assistance 93

Hazard flasher switch 93

Fuses and relays 93

Changing tires 101

Jump starting 101

Wrecker towing 106

Customer Assistance 108

Reporting safety defects (U.S. only) 111

Cleaning 112

Maintenance and Specifications 117

Tilting/Lowering the cab 122

Engine oil 125

Battery 128

Engine Coolant 129

Fuel information 137

Air filter(s) 151

Lug Nut Torque 161

Lubricant specifications 165

Refill capacities 171

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Scheduled Maintenance Guide 173

Normal Scheduled Maintenance and Log 184

Special Operating Conditions and Log 196

Motorcraft Premium Gold Coolant Change Record 197

Index 199

including photocopying, recording or by any information storage and retrieval

system or translation in whole or part is not permitted without written

authorization from Ford Motor Company. Ford may change the contents without

notice and without incurring obligation.

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CALIFORNIA Proposition 65 Warning

WARNING: Engine exhaust, some of its constituents, and

certain vehicle components contain or emit chemicals known to

the State of California to cause cancer and birth defects or other

reproductive harm. In addition, certain fluids contained in vehicles and

certain products of component wear contain or emit chemicals known

to the State of California to cause cancer and birth defects or other

reproductive harm.

CONGRATULATIONS

Congratulations on acquiring your new Ford. Please take the time to get

well acquainted with your vehicle by reading this handbook. The more

you know and understand about your vehicle, the greater the safety and

pleasure you will derive from driving it.

For more information on Ford Motor Company and its products visit the

following website:

• In the United States: www.ford.com

• In Canada: www.ford.ca

• In Mexico: www.ford.com.mx

• In Australia: www.ford.com.au

Additional owner information is given in separate publications.

This Owner’s Guide describes every option and model variant available

and therefore some of the items covered may not apply to your

particular vehicle. Furthermore, due to printing cycles it may describe

options before they are generally available.

Remember to pass on the Owner’s Guide when reselling the vehicle. It

is an integral part of the vehicle.

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Introduction

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SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible

damage to others, your vehicle and its equipment? In this guide, answers

to such questions are contained in comments highlighted by the warning

triangle symbol. These comments should be read and observed.

Warning symbols on your vehicle

When you see this symbol, it is

imperative that you consult the

relevant section of this guide before

touching or attempting adjustment

of any kind.

Protecting the environment

We must all play our part in

protecting the environment. Correct

vehicle usage and the authorized

disposal of waste cleaning and

lubrication materials are significant

steps towards this aim. Information in this respect is highlighted in this

guide with the tree symbol.

SPECIAL NOTICES

New Truck Limited Warranty

For a detailed description of what is covered and what is not covered by

your vehicle’s New Truck Limited Warranty, refer to the Warranty Guide

that is provided to you along with your Owner’s Guide.

Special instructions

For your added safety, your vehicle is fitted with sophisticated electronic

controls.

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Service Data Recording

Service data recorders in your vehicle are capable of collecting and

storing diagnostic information about your vehicle. This potentially

includes information about the performance or status of various systems

and modules in the vehicle, such as engine, throttle, steering or brake

systems. In order to properly diagnose and service your vehicle, Ford

Motor Company, Ford of Canada, and service and repair facilities may

access vehicle diagnostic information through a direct connection to your

vehicle when diagnosing or servicing your vehicle.

Event Data Recording

Other modules in your vehicle - event data recorders - are capable of

collecting and storing data during a crash or near crash event. The

recorded information may assist in the investigation of such an event.

The modules may record information about both the vehicle and the

occupants, potentially including information such as:

• how various systems in your vehicle were operating;

• whether or not the driver and passenger seatbelts were buckled;

• how far (if at all) the driver was depressing the accelerator and/or the

brake pedal;

• how fast the vehicle was traveling; and

• where the driver was positioning the steering wheel.

To access this information, special equipment must be directly connected

to the recording modules. Ford Motor Company and Ford of Canada do

not access event data recorder information without obtaining consent,

unless pursuant to court order or where required by law enforcement,

other government authorities or other third parties acting with lawful

authority. Other parties may seek to access the information

independently of Ford Motor Company and Ford of Canada.

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Cell phone use

The use of Mobile Communications Equipment has become increasingly

important in the conduct of business and personal affairs. However,

drivers must not compromise their own or others’ safety when using

such equipment. Mobile Communications can enhance personal safety

and security when appropriately used, particularly in emergency

situations. Safety must be paramount when using mobile communications

equipment to avoid negating these benefits.

Mobile Communication Equipment includes, but is not limited to cellular

phones, pagers, portable email devices, in-vehicle communications

systems, telematics devices and portable two-way radios.

A driver’s first responsibility is the safe operation of the vehicle.

The most important thing you can do to prevent a crash is to

avoid distractions and pay attention to the road. Wait until it is safe to

operate Mobile Communications Equipment.

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VEHICLE SYMBOL GLOSSARY

These are some of the symbols you may see on your vehicle.

Safety Alert

See Owner’s Guide

Fasten Safety Belt Air Bag-Front

Air Bag-Side Child Seat

Child Seat Installation

Warning

Child Seat Lower

Anchor

Child Seat Tether

Anchor

Brake System

Anti-Lock Brake System

Brake Fluid -

Non-Petroleum Based

Powertrain Malfunction Speed Control

Master Lighting Switch Hazard Warning Flasher

Fog Lamps-Front Fuse Compartment

Fuel Pump Reset Windshield Wash/Wipe

Windshield

Defrost/Demist

Rear Window

Defrost/Demist

Power Windows

Front/Rear

Power Window Lockout

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Child Safety Door

Lock/Unlock

Interior Luggage

Compartment Release

Symbol

Panic Alarm Engine Oil

Engine Coolant

Temperature

Do Not Open When Hot Battery

Avoid Smoking, Flames,

or Sparks

Battery Acid

Explosive Gas Fan Warning

Power Steering Fluid

Maintain Correct Fluid

Level

MAX

MIN

Emission System Engine Air Filter

Passenger Compartment

Air Filter

Jack

Check Fuel Cap

Low Tire Pressure

Warning

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FEDERAL HIGHWAY ADMINISTRATION REGULATION

Regulations such as those issued by the Federal Highway Administration

or issued pursuant to the Occupational Safety and Health Act (OSHA),

and/or state and local laws and regulations may require additional

equipment for the way you intend to use the vehicle. It is the

responsibility of the registered owner to determine the applicability of

such laws and regulations to your intended use for the vehicle, and to

arrange for the installation of required equipment. Your dealer has

information about the availability of equipment which may be ordered for

your vehicle.

ENTERING, EXITING AND/OR CLIMBING ON THIS VEHICLE

You must be careful and deliberate to minimize the possibility of personal

injury from a slip and fall when entering, exiting and/or climbing on this

vehicle. Always use the steps and assist handles before climbing. Do not

skip any steps or assist handles. Use three point contact at all times with

at least two feet and one hand or two hands and one foot firmly placed

during all phases of entering, exiting and/or climbing. Always keep your

shoe soles and hands clean. Keep the steps and assist handles free of

snow, ice, oil, grease, substances or debris. Be sure to use extra care in

bad weather. Avoid wearing thick gloves.

Do not carry items while entering, exiting, and/or climbing. Make

sure you keep a firm grip. Always FACE the VEHICLE STEP and

HANDLE SYSTEM while climbing up and down. Do not climb behind

the cab unless you have three point contact with a step and handle

system at all times.

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To be sure your vehicle is ready to operate, conduct a pre-trip inspection

at the beginning of each work period. Follow the steps listed in this

section to ensure a proper vehicle inspection procedure. The pages in

this section may be produced locally and used on a regular basis.

VEHICLE INSPECTION INFORMATION

Note: Always make sure the parking brake is applied before starting the

engine.

Engine compartment (with engine stopped)

Belts (Fan,

alternator, water

pump and A/C

compressor):

Check for glazing, fraying or cracking. There

should be no more than five - seven cracks per

rib per inch (2.5 cm).

Any leaks: Check for signs of fluid puddles, dripping fluid

on the ground under the engine or the

underside of the engine.

HVAC air inlet: Check for debris, leaves, etc. that may have

collected on the HVAC air inlet grille or inside

the exterior module as this may cause reduced

system performance.

HVAC fresh air filter

(if equipped):

Periodically check the HVAC fresh air filter for

cleanliness.

Exercise great caution when working on vehicle equipped with

an automatic fan clutch. The fan starts in motion only after the

engine coolant reaches a predetermined temperature or the refrigerant

pressure (if equipped with air conditioning) reaches a predetermined

setting. The fan will start at these points with no advance warning.

Never reach near, or permit objects to protrude into the fan blade

radius while the engine is running, as this could result in vehicle

damage, personal injury or death.

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Engine starting (parking brake applied)

Safety/Emergency

equipment:

Prior to entering the cab, verify that the

vehicle is equipped with spare electrical fuses

(if used), three red reflective triangles, a

properly charged and rated fire extinguisher

and wheel chocks. Walk around the vehicle

and check that all steps and grab handles,

inside and out as well as behind, are tight and

clean. Use extreme caution and a three-point

stance at all times. Check door latches for

positive closing, latching and locking.

Starting the engine: Verify the parking brake is set and the

transmission is in P (Park).

When the WAIT TO START indicator light in

the instrument cluster turns off, turn the key

to START.

Accelerator: With the engine running and the transmission

in P (Park), depress the accelerator and verify

that it operates smoothly without any binding

or irregular feel. Remove your foot from the

pedal and make sure the engine returns to idle

speed immediately.

Steering linkage

free play:

Check for excessive free play in the steering

linkages. The steering wheel should have less

than two inches (five centimeters) of free play

at rim of steering wheel.

Brake check: Pump the brake pedal three times, then apply

firm pressure to the pedal and hold it for five

seconds. Once applied, the pedal should not

move; if it does, there may be a leak or

another problem. Do not drive the vehicle

until the problem is fixed.

Parking brake: Check that the parking brake will hold the

vehicle by gently trying to pull forward with

the parking brake applied.

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Engine starting (parking brake applied)

Transmission fluid: With the engine idling at normal operating

temperature and the parking brake applied,

check the automatic transmission fluid. If fluid

needs to be added, refer to Transmission

fluid in the Maintenance and Specifications

chapter.

Front of vehicle

Lights: Make sure all exterior lights illuminate and are

clean. Make sure headlights function on both

high and low beams. Make sure reflectors are

clean and unbroken and of proper color (red

on rear, amber elsewhere). Make sure the

running lights are also clean and unbroken.

Steering gear: Look for missing or loose fasteners, power

steering fluid leaks and damage to power

steering hoses.

Steering linkage: Make sure connecting links, arms and rods are

not worn or cracked; joints, sockets and boot

seals are not worn or loose and that there are

no loose or missing cotter keys, nuts or bolts.

Tow hooks: Front tow hooks should be inspected for

damage or loose mounting. This is particularly

important on vehicles where tow hooks are

frequently used.

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Front suspension

Spring: Inspect for missing, broken or shifted leaves or

leaves that are in contact, or nearly contacting

a tire, rim, brake drum, frame or body

components.

Spring mount: Inspect spring hangers, bolts, bushings, axle

mounting bolts and nuts for cracks, breaks,

wear, damage and tightness.

Torsion bar, Shock

absorber:

Make sure torsion arm is not cracked, broken

or missing. Inspect for cracks, leaks and

missing or broken bolts or bushings.

Note: Never apply grease to spring pads.

Do not operate the vehicle if any suspension conditions listed in

the Front suspension chart are evident. Loss of steering or

suspension could result in property damage, personal injury or death.

Front brakes

Hoses: Check for cracked, worn or frayed hoses. Make

sure all couplings are secured.

Front wheels

Rims: Check for damaged or bent rims. Rims should

not have welding repairs and no rust trails that

indicate it is loose on the wheel.

Lug nuts: Make sure all lug nuts are present and not

loose (look for rust trails around the lug nuts).

There should be no cracks radiating from the

lug bolt holes or distortion of the bolt holes.

Hub oil seal: Check wheel hub oil seal for leaks, and if sight

glass is present, check to see that the oil level

is adequate.

Oil-lubricated front

wheel bearing:

If the hubcap has a transparent window, check

for proper lubrication level. If the hubcap does

not have a transparent window, remove the

rubber fill-plug and check for proper level.

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If a wheel must be changed, obtain expert tire service help.

Mounting and dismounting of tires should only be performed by

a qualified technician using necessary safety procedures and

equipment, otherwise the result could be property damage, personal

injury or death.

Driver area

Engine oil: Use the engine oil dipstick to verify that the

engine oil level is in the operating range.

Engine coolant: Look through the see-through level indicators

on the reservoir and make sure the fluid is in

the proper operating range as marked on the

reservoir. Do not remove pressure cap until

the coolant has cooled.

Power steering fluid: Verify that the fluid level is between the ADD

and FULL marks on the reservoir.

Windshield washer

fluid:

Make sure the reservoir is full.

Brake fluid: Make sure the fluid level is between the

MIN/MAX lines as marked on the reservoir.

Fuel tank: Make sure the fuel tank(s) and cap(s) are

secure. Make sure there is no damage to the

tank(s) and no leaks from the tank(s).

Underbody of vehicle

Driveshaft: Make sure that the driveshaft is not bent or

cracked. Ensure all driveshaft couplings are

secure.

Exhaust system: Make sure the outside visible parts are

securely mounted. Make sure there are no

cracks, holes or severe dents.

Frame: Check for cracks or bends in longitudinal

frame members. Make sure there are no loose,

cracked, bent, broken or missing

crossmembers or crossmember fasteners.

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Maintain adequate clearance between all parts of the exhaust

system and all hoses, wires and lines for engine cooling, brake

system, fuel system, power steering system and electrical system. Heat

damage to hoses, wires or lines may cause vehicle malfunction that

could result in property damage, personal injury or death.

Rear of vehicle

Electrical lines: Make sure electrical lines are not tangled,

crimped or pinched or being dragged against

any truck parts. Electrical line insulation

should not be cut, cracked, chafed or worn.

None of the electrical lines should be spliced

or taped. Check for corrosion on pins and in

electrical sockets to ensure continuity and

reduced heat build-up potential.

Turn signals/Brake

lights:

Make sure both brake lights illuminate when

the brake pedal is applied and each turn signal

flashes. Make sure that the four-way flashers

work properly.

Lights, reflectors: Make sure all exterior lights illuminate and are

clean. Make sure reflectors are clean and

unbroken and of proper color (red on rear,

amber elsewhere). Make sure the running

lights are also clean and unbroken. Rear

running lights must be checked separately

from turn signal, flasher and brake lights.

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Rear springs

Springs: Check for broken or shifted leaves or leaves

that are in contact, or nearly contacting a tire,

rim, brake drum, frame or body components.

Check for missing or broken leaves in the leaf

spring.

Spring mounts: Check for cracked or broken spring hangers,

broken, missing or loose bolts, missing or

damaged bushings, broken, loose or missing

axle mounting parts.

Shock absorber (if

equipped):

Check the shock absorber for cracks or leaks;

there should be no missing or broken

mounting bolts or worn bushings.

Rear brakes

Hoses: Check for cracked, worn or frayed hoses. Make

sure all couplings are secured.

Rear wheels

Spacers: Make sure dual wheels are evenly separated

and that tires are not touching one another.

Rims: Check for damaged or bent rims. Rims should

not have welding repairs and no rust trails that

indicate it is loose on the wheel.

Lug nuts: Make sure all lug nuts are present and not

loose (look for rust trails around the lug nuts).

There should be no cracks radiating from the

lug bolt holes or distortion of the bolt holes.

Transmission

Check the transmission fluid level and shift linkage for proper operation.

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WARNING LIGHTS AND CHIMES

Warning lights and gauges can alert you to a vehicle condition that may

become serious enough to cause expensive repairs. A warning light may

illuminate when a problem exists with one of your vehicle’s functions.

Many lights will illuminate when you start your vehicle to make sure the

bulb works. If any light remains on after starting the vehicle, have the

respective system inspected immediately.

Note: The instrument cluster will self-test when the ignition is turned

on. During this self-test you may hear an audio buzz and/or the gauges

will sweep. This is normal operation

Stop engine: If this red warning

light illuminates while driving, the

vehicle’s cooling system may be

overheating or the engine oil pressure may be dangerously low. An

audible tone will also sound when this light is illuminated. Safely pull off

the road as soon as possible and stop the engine. Continuing to drive

while this light is illuminated may result in extensive engine damage.

Contact your dealership or authorized service center as soon as possible.

Malfunction Indicator Light

(MIL): This yellow warning light

will illuminate to display any

emissions-related issues. Contact your dealership or authorized service

center as soon as possible.

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Warn engine: If this yellow warning

light illuminates while driving, a

problem in the electronic engine

controls has been detected. Contact

your dealership or authorized service center as soon as possible.

Wait to start: With the key in the

ON position, this yellow light will

illuminate if the glow plug heat is

necessary as a starting aid. Wait

until the light goes off before starting. The light should always illuminate

briefly, when the ignition key is in the ON position. Refer to Starting the

engine and Cold weather operation in the Driving chapter. After the

engine starts, the light should remain off. The light should always

illuminate at least momentarily when the engine is cold and the ignition

is turned to ON. If it does not illuminate, the glow plug system should be

checked and repaired promptly to avoid difficulty in cold starting.

To reduce the risk of death or personal injury and the potential

for damage to the engine, do not use volatile starting aids such

as ether, propane or gasoline in the air intake system. The glow plugs

will ignite any of the vapors.

Water in fuel: During refueling, it

is possible for water-contaminated

diesel fuel to be pumped into your

tank. Your vehicle fuel system is

equipped with a fuel filter/water separator to remove water from the

fuel. The yellow WATER IN FUEL light will illuminate when the HFCM

has a significant quantity of water in it.

If the light illuminates when the engine is running, stop the vehicle as

soon as safely possible, shut off the engine, then drain the HFCM. Refer

to Fuel filter/water separator in the Maintenance and Specifications

section for the drain procedure. Allowing water to stay in the system

could result in extensive damage to, or failure of, the fuel injection

system.

Do not drain water separator while engine is running. Fuel may

ignite if separator is drained while engine is running or vehicle is

moving.

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Brake fluid: This red light

illuminates when the brake fluid is

low. An audible tone will also sound

when this light is illuminated. Check the brake master cylinder reservoir

to make sure the fluid level is OK, add if necessary (refer to Brake fluid

in the Maintenance and Specifications chapter for proper checking and

adding procedure). If the level is OK, but the light stays illuminated, do

not drive the vehicle as loss of braking ability may occur. Have the

vehicle towed to your local dealership or authorized service center.

Driving a vehicle with the brake fluid warning light on is

dangerous. A significant decrease in braking performance may

occur. It will take you longer to stop the vehicle. Have the vehicle

checked by your dealer immediately.

Parking brake warning: This red

light illuminates when the parking

brake is engaged.

Anti-lock brake system: This

yellow light momentarily illuminates

when the ignition is in the ON

position. If the light stays

illuminated or continues to flash, a

malfunction has been detected; have the system serviced immediately.

Normal braking is still functional unless the brake fluid warning light also

is illuminated. If the ABS light is not functioning, the trip odometer

display will show “No ABS Ind”.

Check trans: This yellow light

momentarily illuminates when the

ignition is in the ON position. If this

light stays illuminated, a problem

has been detected and the shift pattern may be in default operation

(starts in 5th gear or Drive). Operating limitations may be placed on the

transmission upshifting and downshifting patterns. Have the system

serviced immediately as transmission damage may occur.

ABS

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